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An apparatus for cutting a window covering comprises a saw blade for
cutting a plurality of different types of window coverings. A first
controllable drive moves the saw blade into engagement with a window
covering selected from the plurality of different types of the window
coverings. A second controllable drive for rotates the saw blade. A
preferred saw blade feed rate and a preferred saw blade speed for each of
the plurality of different types of window coverings is determined. The
first variable drive and the second variable drive are controlled based
on the preferred saw blade feed rate and the preferred saw blade speed
for the window covering being cut.

1. A method of cutting a window covering in a cutting machine of the type
having a saw blade comprising: identifying a type of window covering;
determining a preferred operating parameter of the saw blade for the type
of window covering; controlling an operating parameter of the saw blade
speed to be equal to the preferred operating parameter; cutting a window
covering using the saw blade.

7. The method of claim 1 further comprising selecting one type of window
covering from a plurality of different types of window coverings.

8. The method of claim 7 further comprising obtaining a code
corresponding to the one type of window covering.

9. The method of claim 8 further comprising obtaining the code from a bar
code.

10. The method of claim 9 further comprising associating the bar code
with packaging for the one type of window covering.

11. The method of claim 1 further comprising packaging a window covering
in a package such that the ends of the window covering are exposed.

12. The method of claim 11 further comprising clamping the exposed ends
prior to cutting.

13. The method of claim 12 further comprising inserting compressible
inserts in the package prior to clamping the exposed ends.

14. An apparatus for cutting a window covering comprising: a saw blade
for cutting a plurality of different types of window coverings; a first
variable drive for moving said saw blade into engagement with a window
covering selected from a plurality of different types of the window
coverings; a second variable drive for rotating said saw blade; a storage
medium for storing a preferred saw blade feed rate and a preferred saw
blade speed for each of the plurality of different types of window
coverings including the window covering; a processor for controlling the
first variable drive and the second variable drive based on the preferred
saw blade feed rate and the preferred saw blade speed.

15. The apparatus of claim 14 wherein the first variable drive comprises
a first variable speed motor.

16. The apparatus of claim 14 wherein the second variable drive comprises
a second variable speed motor.

18. The apparatus of claim 14 wherein the first variable drive moves a
carriage, said carriage supporting the second variable drive.

19. The apparatus of claim 14 further comprising a second saw blade
spaced from the saw blade.

20. The apparatus of claim 14 further comprising connecting the processor
to a network.

21. The apparatus of claim 14 further comprising a sensor for reading a
machine readable code secured to a package containing the window
covering.

22. The apparatus of claim 19 further comprising a platform in a cutting
chamber where the saw blade and second saw blade are at opposite ends of
the platform.

23. The apparatus of claim 14 wherein the second variable drive comprises
a variable speed transmission.

Description

BACKGROUND

[0001] Window coverings come in a variety of materials including wood,
plastic, fabric, vinyl and aluminum and a variety of styles. Window
coverings are sold as stock, custom and cut-to-size or size-in-store.
Stock window coverings are manufactured in a variety of standard widths
that are intended to fit corresponding standard window sizes. Custom
window coverings are manufactured to specified dimensions per a
customer's specific request. Cut-to-size or size-in-store window
coverings are manufactured in a limited number of sizes that are intended
to be used with a wide range of window sizes. A cutting machine is
provided at the retail outlet that cuts the window covering from the
manufactured or stock size to a desired size.

SUMMARY

[0002] An apparatus for cutting a window covering comprises a saw blade
for cutting a plurality of different types of window coverings. A first
drive moves the saw blade into engagement with a window covering selected
from the plurality of different types of the window coverings. A second
drive rotates the saw blade. A storage medium stores a preferred saw
blade feed rate and a preferred saw blade speed for each of the plurality
of different types of window coverings. A processor controls the first
drive and the second drive based on the preferred saw blade feed rate and
the preferred saw blade speed for the window covering being cut.

[0003] The first and second drives may comprise variable speed motors. The
saw blade may comprise a 10 inch, 52 tooth steel-cutting blade. The first
drive may move a carriage that supports the second drive. The apparatus
may also comprise a second saw blade spaced from the first saw blade. The
apparatus may be connected to a network. A sensor may be used for reading
a machine readable code associated with a package containing the window
covering. A platform may be provided in a cutting chamber where the saw
blades are positioned at opposite ends of the platform. The drives may
comprise variable speed motors and or variable speed transmissions.

[0004] A method of cutting a window covering in a cutting machine of the
type having a saw blade comprises identifying a type of window covering;
determining a preferred operating parameter of the saw blade for the type
of window covering; controlling an actual operating parameter of the saw
blade to be equal to the preferred operating parameter; and cutting a
window covering using the saw blade. The preferred operating parameter
may be saw blade speed or saw blade feed rate. The preferred operating
parameter may be stored in memory. The step of controlling may comprise
controlling a variable speed drive. The method may further comprise
selecting one type of window covering from a plurality of different types
of window coverings. A code corresponding to the one type of window
covering may be obtained from a bar code where the bar code may be
applied to packaging for the window covering. The window covering may be
packaged in a package such that the ends of the window covering are
exposed. The exposed ends may be clamped prior to cutting. Compressible
inserts may place in the package prior to clamping the exposed ends.

BRIEF DESCRIPTION OF THE DRAWINGS

[0005] FIG. 1 is a perspective view of an embodiment of a SIS machine.

[0006] FIG. 2 is a perspective view showing an SIS machine with the outer
housing removed to show a saw.

[0007] FIG. 3 is a perspective view of a saw used in the SIS machine.

[0008] FIGS. 4 and 5 are schematic top views showing operation of a saw to
cut a window covering.

[0009] FIG. 6 is a block diagram of the operating system of the SIS
machine.

[0010] FIG. 7 is a block diagram illustrating a method of operating an SIS
machine.

[0011] FIG. 8 is a perspective view showing a package usable with the SIS
machine of FIG. 1.

[0012] FIG. 9 is a top view showing the package of FIG. 8 packed with a
window covering.

DESCRIPTION OF EMBODIMENTS OF THE INVENTION

[0013] In this application the terms "size-in-store" and "cut-to-size"
refer to window coverings that are manufactured in a limited number of
predetermined stock widths and that may be cut to a desired size using a
window covering cutting machine. The window covering is purposely
manufactured in a size that is wider than the window or other
architectural feature with which the window covering is intended to be
used. It will be appreciated that cut-to-size window coverings may come
in a limited number of different stock widths where each width is
intended to be used with a range of window widths. Whether a single stock
width is provided or several stock widths are provided, the significant
feature of these window coverings is that they are provided in stock
sizes that are cut to the desired size at the retail level and are not
sized for use with a articular window size during the manufacturing
process. The window coverings are typically cut to the specific size
desired by the end user at the point of sale using a cutting machine
provided by the window covering manufacturer.

[0014] The size-in-store (SIS) machine uses controllable variable speed
drives to control the operation of saws such that the system is capable
of cutting a wide variety of materials including wood, plastic, fabric,
vinyl and aluminum and a wide variety of styles including horizontal
blinds, vertical blinds, woven shades, pleated shades, Roman shades and
cellular blinds. The system can also cut the shade panel, head rail and
bottom rail in one pass of the saw. The rotational speed of the saw blade
and the feed rate of the saw blade are controlled on a per cut basis
based on the type of window covering loaded into the SIS machine. The SIS
machine is capable of cutting a wide variety of materials and window
covering styles with a high quality cut.

[0015] FIGS. 1, 2, and 3 show one embodiment of a (SIS) machine 1. It is
to be understood that the invention described herein may be used with any
window cover cutting machine including automatic, semi-automatic and
manual machines that use a saw to cut the window covering. One such
cutting machine is disclosed in copending U.S. application Ser. No.
12/164,839, filed on Jun. 30, 2008 which is incorporated herein by
reference in its entirety. In the illustrated embodiment an internal
frame 2 supports the cutting, measuring and operating systems of the SIS
machine. An outer housing 4 is provided to cover the internal mechanisms
of the SIS machine. An opening 5 is provided to allow access to the
interior cutting chamber 8 of the apparatus to allow a user to place a
window covering 200 into and remove the window covering from the SIS
machine. In the illustrated embodiment opening 5 comprises a drawer that
may be form the illustrated closed position to an open position for
receiving a window covering. The window covering may cut while in the
package or while removed from the package where element 200 encompasses
both situations.

[0016] A platform 20 is provided in cutting chamber 8 adjacent to opening
5 to support the window covering during the cutting operation such that a
user can place a window covering 6 on the platform 20 through opening 5.
The platform 20 comprises a substantially flat surface that is
dimensioned to be able to receive and support a wide range of window
covering sizes.

[0017] In one embodiment, a separate access opening 22 is provided on one
side wall 24 of housing 4 such that a blind may extend through access
opening 22 into cutting chamber 8 from outside of the SIS machine.
Opening 22 is useful for window coverings that are longer than the length
of the SIS machine.

[0018] Referring to FIGS. 2 and 3, a saw 30 may be located at one or both
ends of platform 20 for cutting the window covering to the desired size.
The saw 30 comprises a controllable variable speed drive 34 for rotating
the arbor 38 on which the saw blade 36 is mounted. The variable speed
drive 34 is controlled by the processor 102. The variable speed drive 34
may use a variable speed motor 35. Alternatively, motor 35 may be a
single speed motor coupled to the arbor 38 with a variable speed
transmission 37. Any other suitable arrangement that can control the
rotational speed of the blade 36 may be used. In one preferred embodiment
saw blade 36 comprises a 10 inch, 52 tooth steel-cutting blade. One
suitable blade is sold by LENOX.RTM. as part number 21886ST100052CT.

[0019] The motor 34, transmission 32, arbor 38 and blade 36 are mounted on
a movable carriage 40 that is in turn supported on rails 42. The rails 42
support carriage 40 such that carriage 40 can reciprocate transversely
relative to the platform 20 to bring the saw 30 from a retracted
position, as shown in FIG. 4, to an extended position, as shown in FIG.
5. As the saw blade 36 is moved from the retracted position to the
extended position it contacts and cuts through window covering 200.
Carriage 40 moves saw blade 36 linearly in the direction of arrow A
through the window covering 200 to cut the window covering. FIGS. 4 and 5
show a system where the window covering 200 is positioned in front of a
saw 30 and held in position by a reciprocating clamp assembly 80. A
separate stationary clamp 199 may be used to hold the end of the window
covering 200 during the cutting operation. FIGS. 4 and 5 also show two
saws 30, positioned at each end of platform 20 to cut opposite ends of
the window covering 200. Alternatively, one saw may be used where the
orientation of window covering relative to the saw is reversed.

[0020] Referring to FIG. 3, to move platform 40, a controllable variable
speed drive 43 is provided that is controlled by computing platform 100.
Drive 43 may comprise a motor 44 that is supported on the platform 40 and
that rotates a pinion 46 that engages a rack 48 mounted on frame 2. When
the motor 44 is actuated, the pinion 46 is rotated and through its
engagement with the rack 48 reciprocates platform 40 on rails 42 toward
and away from the window covering. The variable speed drive 43 may
comprise a variable speed motor 44. Alternatively, motor 44 may be a
single speed motor coupled to the pinion 46 by a variable speed
transmission 45. Any other suitable arrangement that can control the
linear rate of travel of the blade 36 may be used.

[0021] Referring to FIG. 6, one embodiment of the operating system of the
SIS machine 1 includes a computing platform 100. The platform is
controlled by a processor 102 which serves as the central processing unit
(CPU) for the platform. Separate PLC controllers 103 may be used with
processor 102 to control the drives of the SIS machine. Memory 104 is
typically divided into multiple types of memory or memory areas such as
read-only memory (ROM), and random access memory (RAM). A plurality of
general-purpose adapters, 106 may be provided. At least one, in this
example, serves to connect the computing platform to a network 108. The
network 108 may be a corporate intranet, a local area network (LAN), the
public switched telephone network, a wireless network, the internet or a
combination of such networks. Computer program code instructions for
implementing the appropriate applications and controlling the SIS machine
are stored on the fixed medium 110. When the system is operating, the
instructions are partially loaded into memory 104 and executed by the CPU
102. Numerous types of general purpose computer systems and workstations
are available and can be used to implement computing platform 100. In
other embodiments, however, a common database may be stored on a database
server such as an SQL server. Available systems include those that run
operating systems such as Windows.TM. by Microsoft, various versions of
UNIX.TM., various versions of Linux.TM., and various versions of Apple's
Mac.TM. OS. A user interface 112 such as a touch screen, keyboard and
monitor, audio speakers or the like is provided to receive input from the
user and to display output to the user. Other user interface devices may
be used such as voice recognition, wireless communication technology, joy
sticks, thumbwheels or the like. User interface 112 is intended to
include any apparatus that allows the user to input data to the system
and/or that allows the system to display information to the user.

[0022] A computer program which implements parts of the invention through
the use of a system like that illustrated in FIG. 6 can take the form of
a computer program residing on a computer usable or computer readable
tangible storage medium such as a diskette. A computer program product
containing the program of instructions can be supplied in such a form,
and loaded on the machines involved, either directly, or over a network
108. The medium may also be a stream of information being retrieved when
the computer program product is "downloaded" through the network 108. The
computer-usable or computer-readable medium may be, for example but not
limited to, an electronic, magnetic, optical, electromagnetic, infrared,
or semiconductor system, apparatus, device, or propagation medium. Other
examples of a tangible computer-readable medium would include a portable
computer diskette or portable fixed disk, an optical fiber, a compact
disc read-only memory (CD-ROM), and a digital versatile disc read-only
memory (DVD-ROM).

[0023] Because the SIS machine uses a saw as the cutting device, the SIS
machine may be used to cut window coverings either in or out of the
packaging. Further, because the SIS machine uses controllable variable
speed drives 34, 43, the SIS machine may cut a wide variety of types of
window coverings including, but not limited to, wood, plastic, fabric,
vinyl and aluminum and a variety of styles including, but not limited to,
horizontal blinds, vertical blinds, woven shades, pleated shades, Roman
shades and cellular blinds. Saw 30 can also cut the shade panel and the
head rail and bottom rail in one cut. The rotational speed of the saws
and the feed rate of the saws can be controlled on a per cut basis based
on the type of window covering loaded in the SIS machine to provide a
high quality cut.

[0024] Because the computing platform 100 is connected over network 108 to
the blind manufacturer 111, service provider 109 and/or retail outlet
113, information may be remotely transmitted between these entities and
the SIS machine. The software running the SIS machine can be remotely
updated to change the operating parameters of the SIS machine including
the operating parameters of the saw such as blade feed rate and blade
speed.

[0025] Referring to FIGS. 4 and 5, a bar code 220 may be associated with
or fixed to the package containing the window covering or directly to the
window covering (if removed from the package) 200. The bar code may also
be provided on a separate flip card. The bar code 220 is in a machine
readable form that is readable by a sensor 122 such as an optical
scanner. The bar code 220 identifies the specific type of window covering
using a unique code. In one embodiment, the code from bar code 220 is
used by the processor 102 to obtain from a look-up table 230 stored in
memory 104, or retrieved from a remote data base, the detailed product
identification information for the window covering. The bar code 220 may
be replaced by radio frequency identification (RFID) tags or other
suitable identification technology. The user may also input a code or
blind type manually using interface 112.

[0026] The computing platform 100 uses the obtained product identification
information to control the operating parameters of the SIS machine. The
applicants of the present invention have determined that the saw
operating parameters, feed rate and speed, can be changed for different
window covering types to produce the high quality cuts. Other saw
operating parameters may also be controlled to control cut quality. A
quality cut should minimize: the number of defects per linear inch of
drop; burning that results in the discoloration of slat and bottom rail
ends due to excessive heat; chipping that results in the tearing off of
fragments of finished wood surfaces; and splintering that results in
fractures along the length of the slats. The applicants have discovered
that these effects can be minimized by controlling the saw operating
parameters blade feed rate and blade speed. The "speed" of the saw blade
is defined as the rotational speed of the rotating blade and the "feed
rate" of the blade is the linear speed at which the saw blade is moved
through the window covering being cut. The optimal predetermined blade
speed and blade feed rates for various types of window coverings has been
discovered as set forth below:

[0027] Because the type of window covering is obtained by the computing
platform from the bar code 220, manually via interface 112 or otherwise,
the processor 102 may refer to the look-up table 230 to determine the
predetermined preferred feed rate and speed for the selected type of
window covering. Based on this information, the computing platform 100
controls the drives 34 and 43 to control the speed of the blade and the
feed rate of the blade through the window covering. A default speed and
feed rate may also be provided for types not otherwise listed.

[0028] Because the drives 34 and 43 are controlled by processor 102, the
preferred speeds and feed rates may be updated. The speeds and feed rates
may be changed based on changes in materials, window covering designs or
the like or to add new window covering types. Moreover, because the
computing platform 100 may be connected to a manufacturer or service
provider over network 108 these changes may be remotely downloaded to the
computing platform 100.

[0029] The speeds and/or feed rates may also be varied for different
components of the same window covering. For example, the saw 30 may be
operated at a first feed rate and/or speed when cutting a steel head rail
on a window covering and a second feed rate and/or speed when cutting the
wood slats on the same window covering. Using the look-up table 230 the
variable drives 34 and 43 may be controlled to change these operating
parameters during a single cutting feed. The change may be based on
elapsed time or distance traveled. For example, the feed rate or speed
may be changed after a predetermined period of time has elapsed from the
initiation of the cut or after the carriage 40 has moved a predetermined
distance. Both the elapsed time and the distance traveled may be related
to the location of the saw blade 36 relative to the window covering. For
example, the distance traveled or elapsed time can be related to the
position of the saw when it cuts through the head rail such that after
the predetermined time elapses or the predetermined distance is traveled
the head rail is presumed cut. The drives 34 and 43 are then controlled
to change the operating parameters of the saw prior to cutting the
remainder of the window covering. Another factor that has been determined
to affect cut quality is the ability of the machine to tight pack the
window covering components against one another during the cutting
operation. One embodiment of a suitable package is shown in FIGS. 8 and
9. Package 200a consists of an open-ended box or sleeve 70 that is a
rectangular container that is open at both ends 72. The window covering
200b is oriented in box 70 such that it is centered in the box. The head
rail, slats and bottom rail extending along the long axis of the box 70
and the ends of the window covering extend beyond the open ends 72 of the
box 70 and are exposed.

[0030] For transport, storage and display purposes end caps 74 cover the
open ends of the box 70. The end caps 74 may be secured to the box 70 by
any releasable connection including a shrink wrap, adhesive, tear-away
tabs or the like. The end caps 74 are removed from box 70 prior to
cutting and may be replaced on the box 70 after the cutting operation to
retain the cut window covering 200b in box 70.

[0031] With the package described above the window covering components are
exposed such that clamp 199 applies the clamping force directly to the
head rail (or other window covering component), rather than on the
package containing the window covering. As a result, the clamping force
compresses the window covering components into tight engagement with one
another creating a tight pack.

[0032] Another device to create a tight pack is the use of inserts shown
in FIG. 9. Inserts 60 may be disposed between the window covering
components where the inserts 60 allow the clamp to better compress the
window covering components together. The inserts 60 comprise rectangular
blocks of relatively stiff but moderately compressible material such as
chip board. Chip board is pressed fiber thick paper, usually made from
recycled paper. The inserts 60 fit between adjacent slats of the window
covering. The inserts 60 are dimensioned to extend for approximately the
depth of the slats and to extend from the end of the slats through the
cut zone. In one embodiment the inserts 60 are approximately 4 inches
wide and 1/16 of an inch thick. When the clamp 199 compresses the window
covering, the inserts 60 are trapped and compressed between adjacent
window covering components. It has been found that placing inserts 60
between the head rail 4 and top slat 2a, between the bottom rail 6 and
the bottom slat 2b, and positioning three additional inserts 60 at
equally spaced intervals along the slats provides the required tight
pack. Inserts may also be placed between the bottom rail and box 70. It
has also been determined that doubling the thickness of the insert
between the head rail 4 and top slat is most effective. The tight pack
may be created and the inserts inserted into the blind either during
initial packaging of the window covering by the manufacturer or at the
time of the cut by the SIS machine operator.

[0033] A method of cutting a window covering will be described. Preferred
operating parameters, blade speed and blade feed rate, for a saw for a
plurality of different types of window blinds are developed (Block 701).
The preferred operating parameters are accessible to the SIS machine from
a local data base or from a remote location such as a server. (Block
702). The SIS machine is also provided with at least one saw blade where
the saw blade is controlled by a first controllable variable speed drive
that controls feed rate and a second controllable variable speed drive
that controls speed (Block 703). A user selects one type of window
covering from the plurality of different types of window coverings (Block
704). The type of the selected window covering is received by the
computing platform using bar code 220, manual interface 112 or by some
other means and is identified (Block 705). The type of window covering is
used by the processor 102 to determine the preferred operating
parameters, one or both of a blade feed rate and a blade speed, for the
type of window covering from the stored preferred parameters (Block 706).
The computing platform 100 controls the first controllable variable speed
drive and/or the second controllable variable speed drive to control one
or both of the blade speed or the blade feed rate based on the preferred
operating parameters (Block 707). Clamp 199 may be extended to clamp the
package or to directly clamp the window covering to create a tight pack
(Block 708). The first drive and second drive are controlled such that
the actual speed of the saw blade and/or the actual feed rate of the saw
blade equal the preferred speed and/or the preferred feed rate for the
selected type of window covering and the window covering is cut at the
preferred parameters (Block 709). It will be understood that although the
preferred speed and preferred feed rate are defined with specificity the
actual speed and feed rate are considered to be equal to the preferred
speed and feed rate if the actual and preferred values are within a the
operating margin of error of the system. The window covering components
may be in a tight pack where the window covering elements are packaged in
a box with open ends such that they may be directly clamped and inserts
are inserted between selected components (Block 710).

[0034] Specific embodiments of an invention are described herein. One of
ordinary skill in the art will recognize that the invention has other
applications in other environments. In fact, many embodiments and
implementations are possible. The following claims are in no way intended
to limit the scope of the invention to the specific embodiments described
above.